7.5 clutch release cover - harley-davidson-sweden.se

HOMEMAIN DRIVE GEAR 7.7REMOVAL7970NOTELeave the transmission case in the frame unless the caseitself requires replacement. For illustration purposes, somephotographs may show the case removed.1. Remove the exhaust system in two sections. See Section3.7 REMOVING ENGINE FROM CHASSIS, steps 3-9.2. Remove the shifter cam and shifter fork assemblies. SeeSection 7.4 SHIFTER CAM ASSEMBLY/SHIFTERFORKS, DISASSEMBLY.3. Remove the primary chaincase cover. Remove theclutch assembly, primary chain, and compensatingsprocket components. Remove the starter jackshaftassembly and primary chaincase. See Section 6.5 PRI-MARY CHAINCASE, REMOVAL.RearIndentSideDoor4. Remove oil filler spout and starter. See Section 5.4STARTER, REMOVAL, steps 6-12.5. Remove the bearing inner race from the transmissionmainshaft. See Section 6.5 PRIMARY CHAINCASE,MAINSHAFT BEARING INNER RACE, REMOVAL.6. See Figure 7-27. Remove the six socket head screws(bottom four with flat washers) to free both the side doorand transmission exhaust bracket from the transmissioncase. Pull the side door, mainshaft and countershaftfrom the transmission case as a single assembly.Remove and discard the door gasket.NOTEDO NOT USE A HAMMER TO REMOVE THE SIDE DOOR.If the side door sticks or binds on the locating dowels, gentlypry open using the indents at each side of the door. See Figure7-27.7. Remove the two socket screws and lockplate to free thesprocket nut. Remove the sprocket nut. Use an airimpact wrench for best results.NOTEThe transmission sprocket nut has left handed threads. Turnthe nut clockwise to remove from the main drive gear.8. Moving to rear wheel, remove E-clip and loosen hex nuton right side of axle. Moving to left side, turn adjustercam in a counterclockwise direction until belt tension isrelieved. Remove the belt from the transmissionsprocket.9. Remove the transmission sprocket, spacer sleeve, mainshaftoil seal and quad seal.Figure 7-27. Remove Transmission Side Door1WARNINGAlways wear proper eye protection when removing retainingrings. Use the correct retaining ring pliers. Verifythat the tips of the pliers are not damaged or excessivelyworn. Slippage may propel the ring with enough force tocause eye injury.10. Remove the retaining ring from the roller bearing bore.11. Pull the main drive gear using HD-35316B, MAIN DRIVEGEAR REMOVER AND INSTALLER. See instructionsprovided with the tool.12. Using a block of wood and a hammer, remove the rollerbearing from the transmission case. Discard the bearing.NOTEAlways replace the main drive gear bearing when the maindrive gear is removed. The bearing will be damaged duringthe removal procedure.CLEANING AND INSPECTION1. Clean all parts in solvent except the transmission caseand needle bearings. Blow dry with compressed air.7-22 2004 Touring: Transmission